1.3.6 Fault Finding Chart (continued)
Problem Possible Cause
slipping or shaking from start in
'everse gear
Strong jerk, or distant double
erk, when engaging positions
P
-R', or 'N-R' (below 1500RPM
tngine speed)
'B','E or 'D' clutch defective
Damper
'6' defective (will give the
same symptoms when changing
from 2nd to 3rd gears
Action
Service 1 renew transmission.
Service
1 renew valve block
qeverse lamp does not illuminate Starter inhibit switch faulty.
bulbs, fuses and cables
'unctioning correctly) Faulty selector lever.
io drive or severe delay. Renew
switch.
Renew lever.
Slipping or shaking during initial Position
'R' not
selected.
'orward movement
Strong jerk 'N
-D' (below 1500
3PM engine speed) Select
'R'.
Sear change functions
faulty (in c'
Zhange 1st to 2nd 12nd to 1st Governor dirty.
Shift valve 1-2 sticking.
Zhange 1st to
2nd
Renew governor.
Renew valve block.
Zhange 2nd to 3rd
13rd to 2nd
Governor dirty.
Shift valve 3
-4 sticking.
:hange 2nd to 3rd
Zhange 3rd to
4th I 4th to 3rd Renew
governor.
Renew valve block.
Sudden shifts
Jehicle starts in 2nd gear Governor sleeve sticking.
Shift valve 1
-2 sticking.
Governor sleeve sticking.
Shift valves 1
-2 and 2-3 sticking.
Jehicle starts in 3rd gear Renew
governor.
Renew valve block.
Renew governor.
Service
I renew valve block.
Searbox changes 1st to 3rd
Uo shifts Dirty
oil filter.
Oil level incorrect.
'A' clutch defective.
'D' clutch one
-way clutch faulty.
'A' clutch damaged
'A' clutch faulty.
'A' clutch damper faulty.
Id or warm state)
If there is no debris in sump, renew the
oil filter and oil;
if debris is present in
the sump, renew the transmission.
Check oil level.
Service
I renew transmission.
Service
1 renew transmission.
Service
I renew transmision
Service
1 renew transmission.
Service
/ renew valve block.
Brake
'Cl' and 1 or 'C' faulty I Service / renew transmission
Governor dirty.
I Renew governor.
Shift valve 2-3 sticking.
'B' clutch faultv
Renew valve block.
Service
I renew transmission
Dampers sticking
I Service I renew valve block
Shift valve 2
-3 sticking I Service 1 renew valve block
Governor sticking.
Dampers sticking. Change
governor.
Service
I renew valve block
Issue 1 August 1994 35
ZF Automatic Transmissions Service Manual
a
2.3.6 Fault Finding Chart (continued)
Problem
Starter motor does not operate
'osition 'R' - Reverse
3everse gear inoperative
Slipping and juddering
Harsh
engagement'p-R' chan
'N-R' change (below 1500RPF
engine speed)
Reverse lamp does not
illuminate (bulbs, fuses and
cables functioning correctly)
Possible Cause
Rotary switch adjustment.
Rotary switch wiring fault.
Rotary switch faulty.
Position
'P or 'N' not selected.
vIV2 faulty.
rNire to MV2 earthed.
3il filter dirty.
Damper
'6' faulty.
Clutch
'6' faulty (also no 3rd gear).
Clutch 'D' faulty.
Clutch
'E' faulty (also no engine braking
in 2nd and 3rd gears).
Pressure regulator valve 1 binding
Rotary switch wiring fault.
Rotary switch faulty.
Reverse gear inhibit valve activated.
Main pressure control valve seized (also
no forward drive in 'D' Drive).
'B'Clutch, 'D'Clutch or 'E' Clutch faulty.
Pressure regulator valve 1 binding
'F'Clutch drum sealing rings faulty
causing
loss of 'E' Clutch pressure.
Damper
'6' faulty (also no 2nd to 3rd
shift).
Pressure regulator valve 1 binding
Modulation pressure too high.
Rotary switch faulty.
Rotary switch setting incorrect.
Rotary switch faulty.
Rotary switch wiring fault.
Action
4djust switch.
qectify.
3ectify or renew.
Select 'F" or 'N'.
Renew valve block.
Renew harness.
Clean
/ replace filter and flush out
the
oil cooler and pipes.
Renew valve block.
Renew transmission.
Renew transmission.
Renew transmission.
Renew valve block.
Rectify.
Rectify or renew.
Renew valve block.
Renew valve block.
Renew transmission.
Renew valve block.
Renew transmission.
Renew valve block.
Renew valve block.
Check TCM Fault Codes.
Rectify or renew.
Adjust setting.
Renew.
Rectify.
Issue 1 August 1994 62
